U.S. patent number 11,156,311 [Application Number 16/626,968] was granted by the patent office on 2021-10-26 for armour for flexible pipe comprising a one-way composite profile section and a reinforcing strip.
This patent grant is currently assigned to IFP Energies nouvelles. The grantee listed for this patent is IFP Energies nouvelles. Invention is credited to Fabien Caleyron, Alexandre Damiens, Francois Grosjean, Michael Martinez, Julien Maurice.
United States Patent |
11,156,311 |
Martinez , et al. |
October 26, 2021 |
Armour for flexible pipe comprising a one-way composite profile
section and a reinforcing strip
Abstract
A composite armour for a flexible pipe includes a composite
profile and a reinforcement tape. The composite profile includes
longitudinally oriented reinforcement fibres embedded in a polymer
matrix. The reinforcement tape includes a woven tape comprising
fibres impregnated with a polymer material, in such a way that the
weft thread of the reinforcement tape is orthogonal to the
longitudinal direction of the profile, and the warp thread is
parallel to the longitudinal direction of the profile.
Inventors: |
Martinez; Michael (Saint
Symphorien D'Ozon, FR), Damiens; Alexandre
(Berville-en-Caux, FR), Maurice; Julien (Duclair,
FR), Grosjean; Francois (Charly, FR),
Caleyron; Fabien (Irigny, FR) |
Applicant: |
Name |
City |
State |
Country |
Type |
IFP Energies nouvelles |
Rueil-Malmaison |
N/A |
FR |
|
|
Assignee: |
IFP Energies nouvelles
(Rueil-Malmaison, FR)
|
Family
ID: |
59974573 |
Appl.
No.: |
16/626,968 |
Filed: |
June 19, 2018 |
PCT
Filed: |
June 19, 2018 |
PCT No.: |
PCT/EP2018/066249 |
371(c)(1),(2),(4) Date: |
December 27, 2019 |
PCT
Pub. No.: |
WO2019/002024 |
PCT
Pub. Date: |
January 03, 2019 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20200224800 A1 |
Jul 16, 2020 |
|
Foreign Application Priority Data
|
|
|
|
|
Jun 30, 2017 [FR] |
|
|
17/56.144 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B32B
5/024 (20130101); B29C 70/226 (20130101); B29C
70/083 (20130101); F16L 11/02 (20130101); F16L
11/24 (20130101); B32B 1/08 (20130101); B32B
2597/00 (20130101); B29K 2105/256 (20130101); B32B
2262/106 (20130101); B29C 70/542 (20130101) |
Current International
Class: |
F16L
11/02 (20060101); B32B 5/02 (20060101); B32B
1/08 (20060101); F16L 11/24 (20060101) |
Field of
Search: |
;138/134,137,140
;428/293.4,293.7,297.4,298.1,299.1,299.7 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
International Search Report for PCT/EP2018/066249, dated Jul. 13,
2018; English translation submitted herewith (6 pgs.). cited by
applicant .
N.N.: "CFK Carbon Platten 1,5mm, Hightec-Line Carbon-Shop.at", Jan.
1, 2014 (Jan. 1, 2014), XP055459043, Retrieved from the Internet:
URL:http://www.carbon-shop.at/produkt/cfk-carbon-platten-lmm-hightec-line-
#.WqfweGfdcSk [retrieved on Mar. 13, 2018]. cited by
applicant.
|
Primary Examiner: Brinson; Patrick F
Attorney, Agent or Firm: Fitch, Even, Tabin & Flannery,
LLP
Claims
The invention claimed is:
1. An armor for a flexible pipe, comprising a composite profile and
at least one reinforcement tape, the composite profile comprising
continuous reinforcement fibers embedded in a polymer resin, the
composite profile having a substantially rectangular section and
the reinforcement tape being secured to at least one face of the
composite profile, wherein the reinforcement tape is a woven tape
comprising fibers impregnated with a polymer material, in such a
way that the weft thread of the reinforcement tape is substantially
perpendicular to the longitudinal direction (L) of the composite
profile, and the warp thread of the reinforcement tape is
substantially parallel to the longitudinal direction (L) of the
composite profile.
2. An armor as claimed in claim 1, wherein 50% to 90% of the fibers
of the reinforcement tape are included in the warp thread of the
reinforcement tape.
3. An armor as claimed in claim 1, wherein the fiber volume ratio
of the reinforcement tape is greater than 40%.
4. An armor as claimed in claim 1, wherein the fibers of the
reinforcement tape are carbon fibers.
5. An armor as claimed in claim 1, wherein the thickness of the
reinforcement tape ranges between 5% and 50% of the thickness of
the armor.
6. An armor as claimed in claim 1, wherein the armor comprises a
reinforcement tape arranged on the upper face of the composite
profile.
7. An armor as claimed in claim 1, wherein the armor comprises two
reinforcement tapes arranged respectively on the upper and lower
faces of the composite profile.
8. An armor as claimed in claim 1, wherein the reinforcement tape
is secured to the composite profile by cladding, gluing or
simultaneous stratification with the polymer resin of the profile
during manufacture of the composite profile.
9. An armor as claimed in claim 1, wherein the armor has a
longitudinal stiffness greater than 70% of that of a reference
unidirectional armor.
10. An armor as claimed in claim 1, wherein the volume ratio of
fibers in the composite profile ranges between 50% and 80%.
11. An armor as claimed in claim 1, wherein the fibers of the
composite profile are oriented only in the longitudinal direction
(L) of the composite profile.
12. A flexible pipe for petroleum effluent transport, the flexible
pipe comprising at least one pressure sheath and at least one
tensile armor layer including armors as claimed in claim 1, the
armor layer being arranged outside the pressure sheath.
13. An armor as claimed in claim 1, wherein 60% to 80% of the
fibers of the reinforcement tape are included in the warp thread of
the reinforcement tape.
14. An armor as claimed in claim 1, wherein the fiber volume ratio
of the reinforcement tape is 60%.
15. An armor as claimed in claim 1, wherein the fiber volume ratio
of the reinforcement tape is between 55% and 65%.
16. An armor as claimed in claim 1, wherein the thickness of the
reinforcement tape ranges between 10% and 30% of the thickness of
the armor.
17. An armor as claimed in claim 1, wherein the armor has a
longitudinal stiffness greater than 80% of that of a reference
unidirectional armor.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. national phase application filed under
35 U.S.C. .sctn. 371 of International Application No.
PCT/EP2018/066249, filed Jun. 19, 2018, designating the United
States, which claims priority from French Patent Application No.
17/56.144, filed Jun. 30, 2017, which are hereby incorporated
herein by reference in their entirety.
FIELD OF THE INVENTION
The present invention relates to longitudinal tensile reinforcement
layers (generally referred to as armours) for a flexible tubular
pipe, in particular for petroleum fluid transport. The flexible
pipe can be used in the field of offshore oil exploitation.
The flexible pipes addressed by the present invention consist of an
assembly of different concentric and superimposed layers, referred
to as unbonded because these layers have a certain freedom to move
relative to one another during a bending stress undergone by the
flexible pipes. These flexible pipes meet, among other things, the
recommendations of the normative documents API 17J "Specification
for Unbonded Flexible Pipe" (4.sup.th Edition, May 2014) and API
17B "Recommended Practice for Flexible Pipe" (5.sup.th Edition, May
2014) published by the American Petroleum Institute. The
constituent layers of the flexible pipes notably comprise polymer
sheaths generally providing a sealing function, and reinforcement
layers designed to take up the mechanical stresses, made up of
windings of metal strips, metal wires, various tapes or profiles
made from composite materials.
These flexible pipes are notably used for transporting oil or gas
type hydrocarbons from a subsea equipment located on the seabed, a
wellhead for example, to a floating production unit located at the
surface. Such pipes can be deployed at great depths, commonly more
than 2000 m, and they must therefore be able to withstand a
hydrostatic pressure of several hundred bars. Furthermore, they
must also withstand the very high pressure of the hydrocarbons
transported, and this pressure can also reach several hundred
bars.
When the flexible pipe is in service, it can be subjected to high
static and dynamic loads, which may generate a fatigue phenomenon.
The most severe loads are generally observed in the upper part of
the riser pipes connecting the seabed to the surface. Indeed, in
this area, the flexible pipe undergoes a high static tensile stress
related to the weight of the pipe, coupled with dynamic tensile and
transverse bending stresses related to the motion of the floating
production unit under the effect of the swell and the waves.
Regarding the part of the flexible pipe extending on the seabed
(flowline), the loads applied are essentially static.
The most commonly used unbonded flexible pipes in the offshore
petroleum industry generally comprise, from inside to outside, an
inner carcass consisting of a strip made from stainless steel
profiles and helically wound with a short pitch as coils stapled to
one another, the purpose of said inner carcass being mainly to
prevent collapse of the flexible pipe under the effect of the
external pressure, an inner polymer sealing sheath, a pressure
vault consisting of at least one clipped metal wire helically wound
with a short pitch, said pressure vault being intended to take up
the radial stresses related to the internal pressure, tensile
armour layers consisting of long-pitch helical windings of metal
wires or composite profiles, said tensile armour layers being
intended to take up the longitudinal stresses undergone by the
flexible pipe, and finally an outer sealing sheath intended to
protect the reinforcement layers from the sea water. In the present
application, short-pitch winding refers to any coil having a helix
angle whose absolute value is close to 90 degrees, in practice
ranging between 70 degrees and 90 degrees to the longitudinal axis
of the flexible pipe. The term long-pitch winding refers to any
coil whose helix angle is, in absolute value, less than or equal to
55 degrees to the longitudinal axis of the flexible pipe.
The inner carcass provides sufficient collapse strength for the
flexible pipe to be able to withstand high external pressures,
notably the hydrostatic pressure when the flexible pipe is
submerged at great depth (1000 m, or 2000 m, or even more), or the
external contact pressures undergone during handling and
installation at sea. A flexible pipe comprising an inner carcass is
referred to as of rough bore type because the innermost element is
the inner carcass that provides a rough passage due to the
intervals between the metallic coils of the stapled strip.
The main purpose of the pressure vault is to enable the inner
sealing sheath to withstand without bursting the pressure exerted
by the petroleum fluid transported in the pipe, the outer face of
the inner sealing sheath resting against the inner face of the
pressure vault. The pressure vault also contributes to improving
the collapse strength of the inner carcass, notably because it
limits the possibilities of deformation of the inner carcass under
the effect of the hydrostatic pressure.
The main purpose of the tensile armour layers is to take up
longitudinal stresses, notably those related to the suspended
weight of the flexible pipe when it is installed on the seabed from
a pipe-laying vessel at the surface. In the case of a riser pipe
permanently connecting an installation resting on the seabed to a
surface floating equipment, these longitudinal stresses related to
the suspended weight are exerted permanently. When the pipe is
submerged at great depth, the longitudinal stresses related to the
suspended weight during installation and/or service can reach
several hundred tons.
The tensile armour layers are generally made of metal or a
composite material. The metallic tensile armours conventionally
used for axial reinforcement of the flexible pipes pose a weight
problem at great depth. Indeed, according to the intended
application, there is a depth beyond which the increase in the
section of the steel armours increases the own weight of the line
more than it increases the axial strength of the flexible pipe. The
loading at the top of the riser during production or of the
flowline during installation then exceeds the capacity thereof.
Installing the line then becomes impossible since the suspended
weight is greater than the capacity limit of taking up the stresses
of the laying equipments.
Work has been carried out for several years now to replace these
metal wires with composite material profiles, which afford the
advantage of having a much lower density, and therefore mass, than
metals. These composite profiles must meet, among other things, the
recommendations of the normative document DNV-OS-0501 "Composite
Components" (November 2013) published by Det Norske Veritas. The
mass decrease obtained for the flexible structures has many
consequences: it allows, with the same pipe-laying vessel, to
install flexible pipes at greater depth; it also allows to use
vessels of lower laying capacity, with potentially reduced
installation costs; finally, the decrease in mass of the flexible
pipes used as risers (lines connecting the sea bottom to the
floating surface unit) can have an impact on the sizing of the
floating units. On the other hand, composite tensile armours have a
lower compressive strength than metal tensile armours, which poses
a problem for loadings at the sea bottom dominated by a high
external pressure.
The composite materials that are discussed here for the application
of longitudinal armours are made of continuous reinforcement fibres
(typically carbon, glass, aramid fibres, . . . ) embedded in a
polymer resin (thermosetting, thermoplastic, . . . ). The current
research work mainly focuses on a carbon-fibre composite material
with an epoxy type thermosetting resin matrix, but this is not
exclusive.
Even though it is possible to consider other manufacturing
processes for this type of material, the one selected for
manufacturing the composite armours is pultrusion, which allows to
readily produce a product of very great length with the fibres
oriented longitudinally so as to obtain the greatest strength in
this direction. When there are only fibres oriented in the
longitudinal direction, the composite is referred to as
unidirectional.
The advantage of unidirectional composites is their very high
mechanical strength in the direction of the fibres but, in
contrast, their drawback is their low transverse strength. Indeed,
although mainly stressed in the longitudinal direction, the armours
of flexible pipes also undergo stresses in the transverse
directions (transverse bending, compression in the thickness of the
composite profile and torsion of the composite profile), both
during manufacture of the flexible pipe upon winding of the armour
wire and during service.
The transverse stresses undergone by the armours can result in
longitudinal cracks, notably when the composite profile is applied
onto the flexible pipe upon loading. Indeed, transverse loading
stresses only the polymer matrix, which has a low elongation at
break. FIGS. 1a and 1b respectively illustrate the initial
configuration of the unidirectional composite profile and the
application of the unidirectional composite profile onto the
flexible pipe upon loading. In these figures, reference D2
designates the direction of applying the armour wire and reference
D1 shows a transverse direction. For such a profile, an incipient
crack AR may appear when applying the profile against the flexible
pipe, notably on the outer surface of the armour.
BACKGROUND OF THE INVENTION
Patent EP-1,066,485 (equivalent WO-99/49,259) provides a solution
for solving this transverse crack risk by adding a film on at least
one face of the composite profile forming the armour. This film,
also referred to as mat, is a layer of non-woven fibres which
affords the advantage of having no preferential reinforcement
direction and a low fibre volume ratio. The mat is added on at
least one of the faces of the armour so as to reinforce it
mechanically against the bending and torsional stresses undergone
during the winding step, upon manufacture of the flexible pipe.
Furthermore, the mat allows to improve the resistance of the armour
to the abrasion process between profiles. For reasons of improved
abrasion strength, but also for cost reasons, the mats used to date
were made from aramid fibres.
There are two limitations to the use of mat layers for reinforcing
unidirectional composites in the transverse directions: the fibre
volume ratio being low and the fibres being randomly oriented, the
reinforcement effect of this layer is low, and it is all the lower
as the thickness of the profile is great, and aramid fibres being
hygroscopic, the environment of the annulus of the flexible pipes
(presence of water, gas, high temperatures) may lead to a
degradation of the properties of this layer during service.
To overcome these drawbacks, the present invention relates to a
composite armour for a flexible pipe. The armour comprises a
composite profile and a reinforcement tape. The composite profile
consists of longitudinally oriented reinforcement fibres embedded
in a polymer matrix. The reinforcement tape consists of a woven
tape comprising fibres impregnated with a polymer material, in such
a way that the weft thread of the reinforcement tape is orthogonal
to the longitudinal direction of the profile, and the warp thread
of the tape is parallel to the longitudinal direction of the
profile. Thus, the reinforcement tape comprising fibres along these
directions allows to improve the transverse behaviour of the armour
and to prevent incipient cracks, while guaranteeing mechanical
properties (notably longitudinal strength and transverse strength),
a size and a mass suited to the constraints related to the
manufacture and use of a flexible pipe.
SUMMARY OF THE INVENTION
The invention relates to an armour for a flexible pipe, comprising
a composite profile and at least one reinforcement tape, said
composite profile consisting of continuous reinforcement fibres
embedded in a polymer resin, said composite profile having a
substantially rectangular section and said reinforcement tape being
secured to at least one face of said composite profile. Said
reinforcement tape is a woven tape comprising fibres impregnated
with a polymer material, in such a way that the weft thread of said
reinforcement tape is substantially perpendicular to the
longitudinal direction of said composite profile, and the warp
thread of said reinforcement tape is substantially parallel to the
longitudinal direction of said composite profile.
Advantageously, 50% to 90%, preferably 60% to 80% of said fibres of
said reinforcement tape are included in said warp thread of said
reinforcement tape.
Advantageously, the fibre volume ratio in said reinforcement tape
is greater than 40% and it is preferably 60%.
According to an embodiment, said fibres of said reinforcement tape
are carbon fibres.
According to an implementation, the thickness of said reinforcement
tape ranges between 5% and 50% of the thickness of said armour,
preferably between 10% and 30% of the thickness of said armour.
According to an aspect, said armour comprises a reinforcement tape
arranged on the upper face of said composite profile.
According to a feature, said armour comprises two reinforcement
tapes arranged on the upper and lower faces of said composite
profile.
According to an option, said reinforcement tape is secured to said
composite profile by cladding, gluing or simultaneous
stratification with said polymer resin of said profile during
manufacture of said composite profile.
According to an implementation, said armour has a longitudinal
stiffness greater than 70% of that of the reference unidirectional
armour, and preferably greater than 80%.
Preferably, the fibre volume ratio in said composite profile ranges
between 50% and 80%.
According to an embodiment, said fibres of said composite profile
are oriented only in the longitudinal direction of said composite
profile.
Furthermore, the invention relates to a flexible pipe for petroleum
fluid transport, said flexible pipe comprising at least one
pressure sheath and at least one tensile armour layer including
armours according to one of the above features, said armour layer
being arranged outside said pressure sheath.
BRIEF DESCRIPTION OF THE FIGURES
Other features and advantages of the composite armour according to
the invention will be clear from reading the description hereafter
of embodiments given by way of non limitative example, with
reference to the accompanying figures wherein:
FIGS. 1a and 1b, already described, respectively illustrate the
initial configuration of the unidirectional composite profile and
the unidirectional composite profile applied onto a flexible pipe
during loading,
FIG. 2 illustrates an armour according to an embodiment of the
invention, and
FIG. 3 illustrates a flexible pipe comprising an armour according
to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to an armour for a flexible pipe,
notably an armour withstanding tensile stresses or tensile armour.
The armour comprises a composite profile and at least one
reinforcement tape. An armour is understood to be a flat element
whose length is very great in relation to the other dimensions:
width and thickness. The armour can have a substantially
rectangular section. The composite profile is also a flat element
whose length is very great in relation to the other dimensions. The
composite profile can have a substantially rectangular profile.
According to the invention, the composite profile can be a
unidirectional composite profile: the composite profile consists of
threads or strands comprising a set of continuous reinforcement
fibres embedded in a polymer resin, the reinforcement fibre strands
being oriented only in the longitudinal direction of the profile.
Thanks to the unidirectional composite, the composite profile and,
a fortiori, the armour have a great mechanical strength in the
direction of the fibres, i.e. in the longitudinal direction of the
armour.
According to the invention, the reinforcement tape is secured to at
least one face of the composite profile. Advantageously, the
reinforcement tape can also be a flat element whose length is very
great in relation to the other dimensions. The reinforcement tape
can have a substantially rectangular section. The reinforcement
tape is a woven tape comprising continuous fibres assembled in
threads or strands, impregnated with a polymer material. According
to the invention, the reinforcement tape is designed in such a way
that the weft thread of the reinforcement tape is substantially
perpendicular to the longitudinal direction of the composite
material (in other words, the weft thread of the reinforcement tape
is parallel to the width of the armour), and the warp thread of the
reinforcement tape is substantially parallel to the longitudinal
direction of the composite profile (in other words, the warp thread
is parallel to the length of the armour). The weft thread is the
thread of a fabric oriented in the direction of the width of the
fabric (therefore of the reinforcement tape). In the opposite
direction, the warp thread is oriented along the length of the
fabric (therefore of the reinforcement tape). The fabric is made by
interlacing these two threads. Such a reinforcement tape design
allows to have fibres in the longitudinal direction and in the
transverse direction, which allows to improve the transverse
behaviour of the armour and to prevent incipient cracks while
maintaining a great mechanical strength in the longitudinal
direction of the armour. The reinforcement tape preferably covers
the entire width of the composite profile. Besides, the
reinforcement tape can extend over substantially the entire length
of the composite profile.
In order to optimize the transverse strength of the armour, the
distribution of the fibres in the reinforcement tape can be as
follows: 50% to 90%, preferably 60% to 80% of the reinforcement
tape fibres are included in the warp thread of the reinforcement
tape, and 10% to 50%, preferably 20% to 40% of the reinforcement
tape fibres are included in the weft thread of the reinforcement
tape.
A low distribution value of the fibres in the warp thread of the
reinforcement tape is more effective in terms of transverse
reinforcement of the armour. However, weaving of the tape is more
difficult and longer to perform, hence uneconomical.
The thickness of the reinforcement tape can vary to nearly the
total thickness of the armour if the entire armour is to be
reinforced in the transverse direction, but one may choose to
preferably provide only part of the armour thickness with a tape.
According to an embodiment, the thickness of the reinforcement tape
can represent 5% to 50% of the total armour thickness, and
preferably the thickness of the reinforcement tape represents 10%
to 30% of the total armour thickness, so as to optimize the use of
a unidirectional tape, notably for the longitudinal strength and
for armour cost reasons. In another embodiment of the invention,
the total thickness of the reinforcement tape is substantially
equal to the thickness of the armour and it is made up of the
superimposition of several layers of thickness less than the total
thickness of said tape, so that the sum of the thicknesses of said
layers is substantially equal to the thickness of the armour. This
superimposition of layers can be seen as a superimposition of
several reinforcement tapes of small thickness, some microns for
example. For example, the superimposition comprises between one and
ten layers, preferably between two and five layers.
According to a feature of the invention, the armour reinforced with
a reinforcement tape can have a longitudinal stiffness greater than
70% of that of the reference unidirectional armour and preferably
greater than 80%, so as to obtain good mechanical properties in the
longitudinal direction of the armour. Stiffness is the
characteristic indicating the resistance to elastic deformation of
a body. Therefore, the thickness of the reinforcement tape and the
distribution of the fibres in the direction of the warp thread can
be selected so as to optimize the mechanical properties in the
longitudinal direction of the armour while reinforcing it
significantly in the transverse direction.
According to an embodiment of the invention, the volume ratio of
fibres in the reinforcement tape can be greater than 40%, it can
preferably range between 55% and 65%, and more preferably it can be
substantially 60%. The fibre volume ratio is understood to be the
ratio of the volume occupied by the fibres to the total volume of
the reinforcement tape. Such a fibre volume ratio in the
reinforcement tape allows to obtain good mechanical properties, and
it allows the reinforcement tape to keep a protective and load
transfer function. In particular, for a fibre volume ratio of 60%,
a good compromise between the mechanical properties and the
protective function of the reinforcement tape is obtained.
According to an embodiment of the invention, the fibres of the
reinforcement tape can be glass, aramid, carbon, high-modulus
polyethylene fibres, etc. For example, glass fibres allow carbon to
be insulated and they prevent coupling with steels, and therefore
galvanic corrosion. Aramid fibres also enable electrical insulation
and they provide the armour with high tribological properties.
Preferably, the fibres of the reinforcement tape can be carbon
fibres for chemical inertia reasons, notably in the application for
flexible pipes, for their good specific mechanical properties (in
relation to the density thereof) and for economic reasons.
Furthermore, carbon fibres help prevent degradation problems that
may exist for aramid fibres, notably hygrothermal degradation.
Preferably, the strands (or threads) formed by assembling the
fibres of the reinforcement tape have different diameters. The
diameter of the strand depends on the number of fibres it consists
of. Typically, a strand comprises several thousand fibres, this
number of fibres being symbolized by the number of K. For example,
a strand consisting of 12,000 fibres is referred to as "12K".
In the present invention, the diameter of the strands can for
example range between 1K and 48K, preferably between 3K and 12K.
Thus, the various "warp thread/weft thread" (or "weft thread/warp
thread") pairs feasible to produce the reinforcement tape are for
example of "3K/3K", "3K/6K", "3K/12K", "6K/6K", "6K/12K" and
"12K/12K" type.
Advantageously, a weft thread of maximum diameter 6K is selected in
order to facilitate weaving of the reinforcement tape.
The polymer material of the reinforcement tape with which the
fibres are impregnated can be selected from among a thermoplastic
or thermosetting polymer material. According to an example
embodiment, the polymer material can be a resin of thermosetting
type such as an epoxide resin, a vinylester resin, a cyanate resin,
etc., or a resin of thermoplastic type such as a polyolefin, a
polyamide, a fluoropolymer, a polyaryletherketone (PAEK), a
polyphenylene sulfide (PPS), etc. Preferably, the polymer material
selected for the reinforcement tape can be the same as that of the
polymer resin of the unidirectional composite profile, which
improves the cohesion of the assembly. Advantageously, in the
embodiment of a reinforcement tape consisting of the
superimposition of several layers, the same polymer material can be
selected for each layer so as to improve the overall cohesion.
The composite profile can consist of continuous reinforcement
fibres selected from among carbon, glass, aramid fibres embedded in
a polymer resin, notably thermosetting or thermoplastic, in
particular an epoxide, vinylester, cyanate, etc., resin, or a
thermoplastic type resin such as a polyolefin, a polyamide, a
fluoropolymer, a polyaryletherketone (PAEK), a polyphenylene
sulfide (PPS), etc.
The volume ratio of fibres within the composite profile can range
between 50% and 80%. This fibre volume ratio in the composite
profile allows to meet the constraints imposed by flexible pipes,
in particular in terms of longitudinal strength.
According to an embodiment of the invention, the tensile armour
comprises two reinforcement tapes secured to the upper and lower
faces of the composite profile. Thus, a trilayer armour is formed,
this trilayer armour providing armour symmetry, and it requires no
specific precautions upon setting to ensure that the armour is in
the right direction.
When the armour comprises a single reinforcement tape (bilayer
armour), the reinforcement tape is secured to the upper face of the
composite profile. This embodiment with a single reinforcement tape
provides simplified production of the armour and it allows to
reinforce only the face of the composite profile that is likely to
exhibit an incipient crack (see FIG. 1b).
According to an embodiment of the invention, a reinforcement tape
can be secured to at least one lateral face (or to both lateral
faces) of the composite profile. This structure provides mechanical
protection of the composite profile against wear phenomena that may
appear between the various composite profiles that make up the
tensile armour layer.
According to an implementation of the invention, the reinforcement
tape is secured to the composite profile by cladding, gluing or
simultaneous stratification with the polymer resin of the profile
during manufacture of the composite profile. Preferably, securing
the reinforcement tape to the composite profile is done by
simultaneous stratification of the various consecutive layers in
order to optimize the cohesion of the various layers.
Advantageously, in the embodiment of the invention where the
reinforcement tape is made up of the superimposition of several
layers, the tape is also formed by simultaneous stratification.
FIG. 2 schematically illustrates, by way of non-limitative example,
a tensile armour according to an embodiment of the invention. FIG.
2 is a three-dimensional partial view (the length of the armour is
not shown in its entirety) of an armour 1. Armour 1 has a
substantially rectangular section. Armour 1 comprises a composite
profile 2 and a reinforcement tape 5. Composite profile 2 and
reinforcement tape 5 have substantially rectangular sections.
Composite profile 2 is a unidirectional composite profile whose
fibres 4 are oriented longitudinally only, i.e. in the longitudinal
direction L of armour 1. Fibres 4 are embedded in a polymer resin
3. Reinforcement tape 5 is secured to the upper face of composite
profile 2. Reinforcement tape 5 comprises fibres impregnated with a
polymer material. Reinforcement tape 5 is formed in such a way that
the weft thread of reinforcement tape 5 is substantially
perpendicular to longitudinal direction L of composite profile 2,
and the warp thread of reinforcement tape 5 is parallel to the
longitudinal direction of composite profile 2. Reinforcement tape 5
covers the entire length and width of composite profile 2.
Other alternative embodiments can be provided. For example, armour
1 can comprise a second reinforcement tape 5 secured to the lower
face of composite profile 2.
A flexible pipe according to the prior art is schematically
illustrated, by way of non-limitative example, in FIG. 3. This pipe
consists of several layers described hereafter, from the inside to
the outside of the pipe. The flexible pipe is of unbonded type and
it meets the specifications defined in the normative document API
17J.
Inner carcass 6 consists of a metal strip helically wound with a
short pitch. It is intended for collapse strength under the effect
of the external pressure applied on the pipe.
Inner sealing sheath 7 is made by extrusion of a polymer material
generally selected from among polyolefins, polyamides and
fluoropolymers.
Pressure vault 8 made of stapled or interlocked metal wires
provides internal pressure strength in the pipe.
According to the illustration of FIG. 3, tensile armour layers 9
consist of wires (armours) helically wound at angles whose absolute
value with respect to the longitudinal axis of the flexible pipe
ranges between 20 degrees and 55 degrees. The pipe advantageously
comprises two superimposed and crossed layers of tensile armours 9,
as shown in FIG. 3. For example, if the inner tensile armour layer
is wound with a helix angle of 30 degrees, the outer tensile armour
layer is wound with a helix angle of -30 degrees. This angular
symmetry allows to provide torsional balance to the pipe, so as to
reduce the tendency thereof to rotate under the effect of a tensile
force.
When the two superimposed and crossed tensile armour layers 9 are
wound with a helix angle substantially equal to 55 degrees,
pressure vault 3 may optionally be removed because the 55-degree
helix angle imparts good internal pressure strength to tensile
armour layers 4.
Outer sealing sheath 10, also obtained by extrusion of a polymer
material, provides an external protection to the pipe.
The pipe shown in FIG. 3 is of rough bore type, i.e. the fluid
circulating in the pipe is in contact with inner carcass 6.
Alternatively, the pipe can be of smooth bore type. In this case,
the pipe shown in FIG. 3 comprises no inner carcass 6. Polymer
sheath 7 is directly in contact with the fluid circulating in the
pipe. Polymer sheath 10 is sealed. The external pressure forces are
supported by vault 8.
The invention further relates to a flexible pipe comprising at
least one pressure sheath and at least one mechanical reinforcement
element. In the present application, the term "mechanical
reinforcement element" designates all the armour layers used to
take up the longitudinal stresses of the flexible pipe. According
to the invention, the flexible pipe comprises at least one armour
layer including composite armours as described above. Furthermore,
the flexible pipe according to the invention can advantageously
comprise at least one of the other layers of the flexible pipe
described in connection with FIG. 3, notably an inner carcass, an
outer sealing sheath, a pressure vault and/or other additional
layers. Preferably, the flexible pipe according to the invention is
of unbonded type and it meets the specifications defined in the
normative document API 17J.
Using composite armours according to the invention allows to make
the flexible pipe lighter in relation to metallic armours. Besides,
the longitudinal and transverse strength of the composite armours
according to the invention allows to prevent armour breaking and
degradation during use.
The present invention is suited for riser type flexible pipes, for
flowline type flexible pipes and for oil offloading line (OOL) type
flexible pipes allowing offloading of petroleum fluids between a
floating production storage & offloading (FPSO) unit and an
offloading buoy.
The invention is particularly well suited for a flexible pipe used
at great depths, for which the pipe top tension is the most severe
loading for dimensioning the armours.
Application Example
The features and advantages of the armour according to the
invention will be clear from reading the application example
hereafter.
The main application intended for the invention is an armour for a
flexible pipe designed for petroleum fluid transport. This flexible
pipe can run through a water depth by connecting bottomhole
installations (well) and a surface platform (such a flexible pipe
is referred to as riser). In deep sea, this pipe undergoes high
mechanical stresses due to its weight and to the motion of the
platform that is in this case always floating. Making this pipe
lighter allows to reduce the stresses applied thereon and also to
reduce the suspended weight to be supported by the platform. There
are cases where the dimensions of the flexible pipe and the water
depth are such that only a flexible pipe with composite armours can
be envisaged, the top riser for example (i.e. the upper portion of
the flexible pipe). In this example, it is a flexible pipe of
inside diameter 9'' (approximately 228.6 mm) dimensioned for an
internal pressure in operation of 553 bar (approximately 55.3 MPa)
and a water depth of 2140 m.
The critical loads to be supported by the top riser correspond to
the top loading (connection with the platform) and the bottom
loading (connection with the bottom riser, i.e. the lower portion
of the flexible pipe). The top loading encompasses the internal
pressure (line on production), the tension due to the suspended
weight and the bending due to the platform motion, the latter two
being not constant. The bottom loading encompasses the external
pressure (depressurized line) and the tension due to the weight of
the bottom riser, the sum thereof bringing the armours under
compression as a result of the reverse bottom effect.
The solution provided by the prior art in this case is a flexible
pipe with 4 unidirectional composite armour layers of section
14.times.1.65 mm, with a fibre volume ratio Vf=68%. Two new armour
structures according to the invention are proposed here (section
14.times.2.08 mm, Vf=60% for the reinforcement tape and the
composite profile): Example 1 (not in accordance with the
invention): one reinforcement tape, with a fibre distribution in
the warp thread k=0.89 (89%), Example 2 (according to the
invention): a trilayer successively consisting of a first
reinforcement tape with k=0.7, a composite profile and a second
reinforcement tape with k=0.7, the respective thicknesses of the
three layers being 0.39, 1.30 and 0.39 mm, Example 3 (according to
the invention): a bilayer successively consisting of a composite
profile and a reinforcement tape with k=0.7, the respective
thicknesses being 1.30 and 0.78 mm, and the reinforcement tape
being arranged on the outer surface of the composite profile.
These solutions have been dimensioned to provide the same axial
stiffness to the flexible pipe. For each solution, the stresses and
the breaking factor R of the armours are calculated for the top and
bottom loadings of the flexible pipe, by means of a numerical
simulator allowing to fully take into account the multiaxial
character of the loadings.
The maximum value of breaking factor R is given for the different
solutions in Table 1. The thread is considered to be broken for
R.gtoreq.1. Factor R is calculated from the stress state and the
breaking strength in each direction of the thread.
TABLE-US-00001 TABLE 1 Maximum breaking factor for the different
armour structures Armour R.sub.max Prior art: unidirectional armour
with Vf = 68% 1.33 Example 1 1.13 Example 2 0.86 Example 3 0.80
The fibre ratio reduction greatly decreases the value of R.sub.max
in relation to the example of the armour according to the prior
art, but it remains close to 1. However, using a trilayer, and
particularly a bilayer, allows to further reduce the value of
R.sub.max and to fall below 0.9, thus avoiding armour breaking.
Thus, reinforcing the current unidirectional composite profile with
woven tapes or more generally fabrics allows to improve the
transverse strength of the armour while maintaining satisfactory
longitudinal properties. Notably, it is possible to sufficiently
reinforce the armour so as to prevent longitudinal cracks.
* * * * *
References